Fire retardant construction for mattress assembly

ABSTRACT

A mattress assembly having an inner cushioning member, top and bottom mattress covers and a surrounding border strip extending around the periphery of the mattress between the top mattress cover and the bottom mattress cover. In the present invention, the peripheral border strip extending around the periphery of the mattress is secured to the fabric flanges of the top and bottom mattress covers by tiny releasable and flexible hook and loop fastening members. The fire retardant construction includes peripheral welts extending around the periphery of the upper and lower peripheral edges of the peripheral border strip and peripheral welts are provided on the respective fabric flanges of the top and bottom mattress covers which contact and press against respective ones of the welts of the peripheral border strip to thereby restrict passage of oxygen into the interior of the mattress and thus inhibit burning therein.

FIELD OF THE INVENTION

This invention relates to the field of mattresses having a fireretardant construction comprising a mattress assembly having an innercushioning member, top and bottom mattress covers and a surroundingborder strip extending around the periphery of the mattress between thetop mattress cover and the bottom mattress cover. In the presentinvention, the peripheral border strip extending around the periphery ofthe mattress is secured to the fabric flanges of the top and bottommattress covers by tiny releasable hook and loop fastening members. Thefire retardant construction includes a first peripheral welt orcylindrical member somewhat in the form of a lip having an enlargeddiameter extending around the periphery of the upper peripheral edge ofthe peripheral border strip and a second peripheral welt or cylindricalmember somewhat in the form of a lip having an enlarged diameterextending around the periphery of the lower peripheral edge of theperipheral border strip. Such welt or enlarged cylindrical member can becontinuous length of rope enclosed within a folded over portion of themattress fabric. When the peripheral border strip is in place on themattress, the first peripheral welt of the border strip contacts andpresses against a corresponding welt provided on the fabric flange ofthe top mattress cover positioned thereon to face the first peripheralwelt when the border strip is in place on the mattress, and the secondperipheral welt of the border strip contacts and presses against acorresponding welt provided on the fabric flange of the bottom mattresscover positioned thereon to face the second peripheral welt when theborder strip is in place on the mattress.

BACKGROUND OF THE INVENTION

Relevant prior art of which the inventor is aware is set forth in thefollowing patents discovered during his searches for prior art.

U.S. Pat. No. 5,214,809 discloses an articulated mattress for anadjustable bed which has hinge portions between mattress sections forlimited pivotal movement of one section relative to another.

U.S. Pat. No. 5,040,255 discloses a cushion or mattress structurecomprising a box structure with side, top and bottom walls of foammaterial, and cavity within the box to receive encased springs.

U.S. Pat. No. 4,956,884 discloses a modular box spring mattresscomprising a plurality of plate sub units in which coil springs arereceived and held by flexible retaining arms. The sub units havecooperative coupling structures to hold adjacent sub units together.

U.S. Pat. No. 4,868,941 discloses an assembled mattress having an uppersheet with integrally formed sleeves or bellows extending downward and alower sheet with integrally formed sleeves or bellows extending upward,with individual coil springs seated in each of the sleeves or bellows.

U.S. Pat. No. 2,547,840 discloses a sectional mattress comprising threeseparate sections positioned end to end, with one end of a coil springconnected at each end of the middle section and on both sides thereof,having the other end of each coil spring connected to the adjacentmattress section at each opposite end of the middle section.

U.S. Pat. No. 2,446,775 discloses an innerspring mattress constructionmade up of sections which are glued together along facing end walls tomake up a completed mattress.

U.S. Pat. No. 2,249,266 discloses a combined chair and bed having amattress like coil spring cushion supported on a hinged frame whichfolds down into a bed and angularly to form a chair in one position anda recliner in another.

U.S. Pat. No. 2,216,991 discloses three mattress units which areconnected end to end to make a complete mattress. The units areconnected by a transverse cylindrical bar insert on one unit which isreceived in a sleeve have a split cylindrical wall around its throughpassageway on the adjacent unit.

U.S. Pat. No. 1,915,674 discloses a coil spring assembly for makingcushions, comprising four or more coils in a row connected by anelongated endless loop of twisted wire which includes one elongatedstrand connected to one side of each coil in the row and a secondparallel strand connected to the opposite side of each coil in the row,such rows of coils in turn being connected to adjacent rows of coils byC-wires or fasteners known as hog rings.

U.S. Pat. No. 1,459,540 discloses a sectional mattress comprising threeseparate sections that are laid end to end to make up a completemattress and can be interchanged in their relationship to each other.The innersprings within each section are encased in bags.

The inventor's own U.S. Pat. No. 5,435,026 discloses a do-it-yourselftype of mattress which can be put together by the customer afterpurchasing the necessary component parts.

The inventor's own U.S. Pat. No. 5,471,688 discloses a modularinnerspring assembly for a mattress and a modular box spring assembly onwhich the mattress is placed.

The inventor's own U.S. Pat. No. 5,485,639 discloses an S-shaped metalconnecting clip having a spring characteristic to more easily connectthe border wire around the top and bottom of an innerspring assembly tothe top and bottom coils of adjacent coil springs.

The inventor's own U.S. Pat. No. 5,644,811 discloses a mattress havingaccess to materials sandwiched between the mattress covers and theinnerspring or other innercushioning member.

SUMMARY OF THE INVENTION

The present invention constitutes an improvement over the prior art inthat the border strip around the periphery of the mattress assemblyincludes a fire retardant construction. The fire retardant constructionincludes a first continuous welt or cylindrical enlargement along theupper edge of the border strip held in close contact against acorresponding continuous welt or cylindrical enlargement along thefacing portion of the fabric flange hanging down from the top mattresscover, and a second continuous welt or cylindrical enlargement along thelower edge of the border strip held in close contact against acorresponding continuous welt or cylindrical enlargement along thefacing portion of the fabric flange extending upwardly from the bottommattress cover.

In one embodiment, a peripheral retaining band has a width correspondingto the peripheral side wall dimension of the mattress or innercushioningmember. The retaining band usually has an outwardly facing surfacecovered by the same material as the outwardly facing surfaces of the topand bottom mattress covers. On the inwardly facing surface, theretaining band includes tiny hook or loop fasteners of the Velcro typeto releasably interconnect with corresponding tiny hook or loopfasteners on the top and bottom mattress covers or on the fabric flangesof the top and bottom mattress covers.

The retaining band can also be a continuous length of material,preferably having some elasticity, and slipped over the innercushioningmember as well as over the fabric flanges of the top and bottom mattresscovers in place on the innercushioning member. The mattress mayotherwise be of the traditional mattress construction, having aninnercushioning member such as an innerspring assembly, cushioningmaterial over the upper and lower surfaces of the innerspring assembly,a mattress cover over such cushioning materials on both surfaces, withthe fabric flange of the top mattress cover extending downwardly alongand around the peripheral side wall of the mattress assembly and thefabric flange of the bottom mattress cover extending upwardly therealongand therearound. The difference between the present invention and theprior art is that the fabric flanges of the top and bottom mattresscovers have fire retardant welts positioned thereon to contact and pressagainst corresponding fire retardant welts on the inner surface of theperipheral border strip when the tiny fastening hooks and loops of theborder strip and mattress covers are pressed together to releasablyinterconnect the border strip with the mattress covers.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a side elevation view of a mattress in accordance with thisinvention in which the middle portion has been broken away, and in whichportions of the upper and lower edges of the peripheral band extendingaround the mattress have also been broken away to illustrate aperipherally extending rope that is enclosed within folded over portionsof the mattress fabric along both the upper and lower edges of theperipheral band.

FIG. 2 is a section view taken on line 2-2 of FIG. 1, but with a middleportion of the mattress as seen in this section view broken away.

DESCRIPTION OF PREFERRED EMBODIMENT

A mattress assembly 2 in accordance with the present invention comprisesan innercushioning assembly such as an innerspring 4, a top mattresscover 6, a bottom mattress cover 8, and a peripheral border strip 10 inthe form of an elongated band 12 that extends around the entireperiphery 14 of the mattress assembly 2. The elongated band 12 has afirst peripherally extending strip 16 of tiny releasable hook fasteningmembers 18 just below the upper edge 20 of the inwardly facing surface22 of the elongated band 12, and a second peripherally extending strip24 of said tiny releasable hook fastening members 18 just above thelower edge 26 of such inwardly facing surface 22 of the elongated band12.

The elongated band 12 has a first peripherally extending welt orcylindrical enlargement such as a fabric enfolded rope 17 along theupper edge 20 of the elongated band 12 just above the peripherallyextending strip 16 having the tiny releasable hook fastening members 18.The elongated band 12 also has a second peripherally extending welt orcylindrical enlargement such as a fabric enfolded rope 25 along thelower edge 26 of the elongated band 12 just below the peripherallyextending strip 24 having the tiny releasable hook fastening members 18.The rope 17 and 25 may be a continuous length of rope made of hemp orcomparable rope making material, having a diameter of one-eighth of aninch to One-quarter of an inch.

The first peripherally extending strip 16 of releasable hook fasteningmembers 18 releasably interconnect with corresponding tiny releasableloop fastening members 42 secured to the outwardly facing surface 44 ofthe fabric flange 46 and extends around the periphery of the topmattress cover 6 hanging downwardly therefrom. A peripherally extendingwelt or cylindrical enlargement 43 is secured to the outwardly facingsurface 44 of the fabric flange 46 just above the tiny releasable loopfastening members 42, positioned to face and firmly contact the welt 17around the upper edge of the elongated peripheral band 12.

The second peripherally extending strip 24 of such releasable hookfastening members 18 releasably interconnect with corresponding tinyreleasable loop fastening members 42 secured to the outwardly facingsurface 50 of the fabric flange 52 and extends around the periphery ofthe bottom mattress cover 8 projecting upwardly therefrom. Aperipherally extending welt or cylindrical enlargement 53 is secured tothe outwardly facing surface 50 of the fabric flange 52 just below thetiny releasable loop fastening members 42 around the fabric flange 52,positioned to face and firmly contact the welt 25 around the lower edgeof the elongated peripheral band 12.

When the welt 17 along the upper edge of the elongated peripheral band12 is in place and in firm contact with the corresponding welt 43 of thefabric flange of the top mattress cover, and the welt 25 along the loweredge of the elongated peripheral band 12 is in place and in firm contactwith the corresponding welt 53 of the fabric flange 52 of the bottommattress cover, held securely in place by the respective releasable hookand loop fastening members, the welt 17 in firm contact with itscorresponding welt 43 and welt 25 in firm contact with its correspondingwelt 53 provide a fire retardant construction by substantiallypreventing oxygen from reaching interior portions of the mattress tothereby retard and prevent ignition of materials in the interior of themattress.

The mattress having the fire retardant construction in accordance withthis invention has passed a mattress fire prevention test commonly usedas a standard in the mattress industry for mattresses used in publicbuildings. That is the “Flammability Test Procedure for Mattresses ForUse in Public Buildings” described in Technical Bulletin 129 of theState of California which is available to the public, including on theInternet. The purpose of such test is to determine the burning behaviorof mattresses used in public occupancy facilities, such as hospitals andother health care facilities, old age convalescent homes, boardinghouses, college dormitories, residence halls and the like. An elongatedpropane gas burner with spaced apart apertures is positioned parallel tothe bottom horizontal surface of the mattress, one inch from thevertical side panel of the mattress, and ignited. The testing continuesuntil (1) all combustion has ceased, (2) one hour of testing has elapsedor (3) flashover of the mattress being tested appears inevitable.

1. A mattress able to pass an established fire protective test having a fire retarding construction, comprising barrier means releasable from said mattress to be separable therefrom and securable thereto, said barrier means extending around the entire periphery of said mattress when secured thereto to restrict entry of oxygen into the interior portions of said mattress.
 2. A mattress able to pass an established fire protective test as set forth in claim 1, wherein said mattress includes an innercushioning assembly having an upper surface and a lower surface, a top mattress cover over said upper surface of said innercushioning assembly, first insert members between said top mattress cover and said upper surface of said innercushioning assembly, a bottom mattress cover over said lower surface of said innercushioning assembly, second insert members between said bottom mattress cover and said lower surface of said innercushioning assembly, a top mattress cover fabric flange extending downwardly from the peripheral edge of said top mattress cover, a bottom mattress cover fabric flange extending upwardly from the peripheral edge of said bottom mattress cover, a peripheral band extending around the periphery of said mattress, said peripheral band having an upper edge and a lower edge, said barrier means includes a first enlarged diameter welt along said upper edge of said peripheral band, a second enlarged diameter welt along a portion of said top mattress cover fabric flange in facing relation with said first enlarged diameter welt when said peripheral band is in place on said mattress.
 3. A mattress able to pass an established fire protective test as set forth in claim 1, wherein said mattress includes an innercushioning assembly having an upper surface and a lower surface, a top mattress cover over said upper surface of said innercushioning assembly, first insert members between said top mattress cover and said upper surface of said innercushioning assembly, a bottom mattress cover over said lower surface of said innercushioning assembly, second insert members between said bottom mattress cover and said lower surface of said innercushioning assembly, a top mattress cover fabric flange extending downwardly from the peripheral edge of said top mattress cover, a bottom mattress cover fabric flange extending upwardly from the peripheral edge of said bottom mattress cover, a peripheral band extending around the periphery of said mattress, said peripheral band having an upper edge and a lower edge, said barrier means includes a first enlarged diameter welt along said upper edge of said peripheral band, a second enlarged diameter welt along a portion of said top mattress cover fabric flange in facing relation with said first enlarged diameter welt when said peripheral band is in place on said mattress, a third enlarged diameter welt along said lower edge of said peripheral band, a fourth enlarged diameter welt along a portion of said bottom mattress cover fabric flange in facing relation with said third enlarged diameter welt when said peripheral band is in place on said mattress.
 4. A mattress able to pass an established fire protective test as set forth in claim 3, including releasable fastening members to releasably hold said first enlarged diameter welt against said second enlarged diameter welt when said peripheral band is in place on said mattress.
 5. A mattress able to pass an established fire protective test as set forth in claim 4, wherein said releasable fastening members include tiny flexible hook members and corresponding tiny flexible loop members.
 6. A mattress able to pass an established fire protective test as set forth in claim 3, including releasable fastening members to releasably hold said third enlarged diameter welt against said fourth enlarged diameter welt when said peripheral band is in place on said mattress.
 7. A mattress able to pass an established fire protective test as set forth in claim 6, wherein said releasable fastening members include tiny flexible hook members and corresponding tiny flexible loop members.
 8. A mattress able to pass an established fire protective test having a fire retarding construction, comprising barrier means extending around the entire periphery of said mattress to restrict entry of oxygen into the interior portions of said mattress, said barrier means including a length of rope, said mattress including a fabric covering, said rope being enfolded by a portion of said fabric.
 9. A mattress able to pass an established fire protective test as set forth in claim 8, wherein said rope has a diameter of-about one-eighth of an inch.
 10. A mattress able to pass an established fire protective test as set forth in claim 8, wherein said rope has a diameter of any size between one-eighth of an inch and one-fourth of an inch.
 11. A mattress able to pass an established fire protective test having a fire retarding construction, comprising barrier means releasable from said mattress to be separable therefrom and securable thereto, said barrier means extending around the entire periphery of said mattress to restrict entry of oxygen into the interior portions of said mattress, wherein said fire protective test is the “Flammability Test Procedure for Mattresses For Use in Public Buildings” described in Technical Bulletin 129 of the State of California. 